U.S. patent application number 12/013803 was filed with the patent office on 2008-07-03 for method for ventilating a seat.
This patent application is currently assigned to W.E.T. Automotive Systems AG. Invention is credited to Corina S. Alionte, Goran Bajic, Valerija Drobnjakovic, Vladimir Gerasimov, Shaun C. Howick, Syed R. Iqbal, Simone Kohler, Marinko Lazanja, Peter Nagele, Zoran Panic, Vladimir Proseanik, Stefan Stoewe, Piter Ulan, Boris Zlotin.
Application Number | 20080160900 12/013803 |
Document ID | / |
Family ID | 42813288 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080160900 |
Kind Code |
A1 |
Iqbal; Syed R. ; et
al. |
July 3, 2008 |
METHOD FOR VENTILATING A SEAT
Abstract
The present invention relates to a ventilated seat having an
insert with a seat portion, and having a flow control layer with
first and second ports, a spacer having an inlay and a main
portion, and a first fluid barrier where the inlay is substantially
isolated from the main portion by a fluid-tight boundary. The
present invention also relates to a ventilated seat having an
insert with a seat portion and having a first flow control layer
with at least one port, a first and a second spacer, and a fluid
barrier comprising at least one port. The present invention also
relates to a ventilated seat with an insert having a seat portion
and having a flow control layer with a port and a plurality of flow
holes in the seat portion, a spacer, a fluid barrier and at least
one conduit with a plurality of flow holes located adjacent to the
seat portion of the flow control layer. The seat also may include a
fan in fluid communication with the spacer and a fluid conditioning
device. The present invention also relates to methods of
ventilating a seat. The method includes providing a thermoelectric
device (TED) and conditioning air with the TED to provide heating
or cooling and communicating that conditioned air through an insert
with either pushing or pulling the condition air through the
insert.
Inventors: |
Iqbal; Syed R.; (Tecumseh,
CA) ; Alionte; Corina S.; (Windsor, CA) ;
Bajic; Goran; (Belle River, CA) ; Howick; Shaun
C.; (Windsor, CA) ; Panic; Zoran; (Windsor,
CA) ; Drobnjakovic; Valerija; (LaSalle, CA) ;
Lazanja; Marinko; (Windsor, CA) ; Kohler; Simone;
(Ostfildern, DE) ; Nagele; Peter; (Aichach,
DE) ; Stoewe; Stefan; (Mering, DE) ; Zlotin;
Boris; (Southfield, MI) ; Ulan; Piter;
(Southfield, MI) ; Gerasimov; Vladimir;
(Southfield, MI) ; Proseanik; Vladimir;
(Southfield, MI) |
Correspondence
Address: |
DOBRUSIN & THENNISCH PC
29 W LAWRENCE ST, SUITE 210
PONTIAC
MI
48342
US
|
Assignee: |
W.E.T. Automotive Systems
AG
|
Family ID: |
42813288 |
Appl. No.: |
12/013803 |
Filed: |
January 14, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10822405 |
Apr 12, 2004 |
7356912 |
|
|
12013803 |
|
|
|
|
60505806 |
Sep 25, 2003 |
|
|
|
60525959 |
Dec 1, 2003 |
|
|
|
Current U.S.
Class: |
454/229 |
Current CPC
Class: |
B60N 2/5635 20130101;
A47C 7/72 20130101; Y10T 29/49083 20150115; Y10T 29/49353 20150115;
A47C 7/74 20130101; Y10T 29/49826 20150115; Y10T 29/49805 20150115;
Y10T 29/49087 20150115 |
Class at
Publication: |
454/229 |
International
Class: |
F24F 7/06 20060101
F24F007/06; A47C 7/72 20060101 A47C007/72 |
Claims
1-57. (canceled)
58. A method of cooling or heating a cushion with a ventilation
system, comprising the steps of: placing a edge sealed insert over
the cushion and below a surface of an air-permeable cushion cover,
wherein the edge sealed insert including holes defined for fluid
flow; bonding the edge sealed insert with an adhesive to the
cushion; automatically operating the ventilation system upon
detection of the presence of a user by an occupant detection
sensor; drawing ambient air through an annular inlet into a fan;
directing the drawn air past a TED and into the insert;
automatically regulating both the amount of power directed to the
TED and the operating speed of the fan through a control system;
and providing cooling or heating at a rate that ranges from greater
than about 5.degree. C./min.
59. The method according to claim 58, further includes the step of
directing air through a spacer disposed in the edge sealed
insert.
60. The method according to claim 58, further includes providing a
temperature sensor that is employed, after activating the
ventilation system, in communication with a control system for
automatically operating the ventilation system.
61. The method according to claim 58, wherein the ventilation
system and all of functional components of the cushion are
assembled at a remote assembly site, and thereafter transport the
cushion to an automotive assembly line, where the cushion is merely
mounted to a body in white and connected to a vehicle electrical
system.
62. The method according to claim 58, wherein an additional foam
spacer layer is provided and the step of locating the additional
foam spacer layer between the edge sealed insert and the
air-permeable cushion cover.
Description
CLAIM OF PRIORITY
[0001] The present application claims the benefit of U.S.
provisional applications 60/505,806, filed Sep. 25, 2003 and
60/525,959, filed on Dec. 1, 2003.
FIELD OF THE INVENTION
[0002] The present invention relates generally to an insert and
system for providing heating, cooling, ventilation or a combination
thereof to a seat and more particularly to an insert and system for
an automotive vehicle.
BACKGROUND OF THE INVENTION
[0003] For many years the transportation industry has been
concerned with designing seats for automotive vehicles that provide
added comfort to occupants in the seats. Various innovations in
providing seating comfort are discussed in U.S. Pat. Nos.
6,064,037; 5,921,314; 5,403,065; 6,048,024 and 6,003,950, all of
which are expressly incorporated herein by reference. In addition,
other innovations in providing seating comfort are discussed in
U.S. patent application Ser. No. 09/619,171, filed Jul. 19, 2000,
titled "Ventilated Seat Having a Pad Assembly and a Distribution
Device"; U.S. Publication No. 2002/0096931, filed Jan. 5, 2001,
titled "Ventilated Seat"; U.S. Pat. No. 6,629,724, issued Oct. 7,
2003, titled "Portable Ventilated Seat"; U.S. patent application
Ser. No. 10/434,890, filed May 9, 2003, titled "Automotive Vehicle
Seat Insert"; U.S. patent application Ser. No. 10/463,052, filed
Jun. 17, 2003, titled "Automotive Vehicle Seating Comfort System";
and U.S. patent application Ser. No. 10/681,555, filed Oct. 8,
2003, titled "Automotive Vehicle Seating Comfort System", each of
which are expressly incorporated herein by reference for all
purposes.
[0004] In the interest of continuing such innovation, the present
invention provides an improved insert and system for a seat, which
are preferably suitable for employment within or as part of an
automotive vehicle seat and which assist in providing comfort
control to an occupant in the seat.
SUMMARY OF THE INVENTION
[0005] The present invention relates to a ventilated seat having an
insert with a seat portion, and having a flow control layer with
first and second ports, a spacer having an inlay and a main
portion, and a first fluid barrier where the inlay is substantially
isolated from the main portion by a fluid-tight boundary. The
present invention also relates to a ventilated seat having an
insert with a seat portion and having a first flow control layer
with at least one port, a first and a second spacer, and a fluid
barrier comprising at least one port. The present invention also
relates to a ventilated seat with an insert having a seat portion
and having a flow control layer with a port and a plurality of flow
holes in the seat portion, a spacer, a fluid barrier and at least
one conduit with a plurality of flow holes located adjacent to the
seat portion of the flow control layer. The seat also may include a
fan in fluid communication with the spacer and a fluid conditioning
device.
[0006] The present invention also relates to methods of ventilating
a seat. The method includes providing a thermoelectric device (TED)
and conditioning air with the TED to provide heating or cooling and
communicating that conditioned air through an insert with either
pushing or pulling the condition air through the insert.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] In the drawings:
[0008] FIG. 1 shows an exploded view of a first embodiment of the
insert.
[0009] FIG. 2 shows a schematic view of a system including the
first embodiment of the insert.
[0010] FIG. 3 shows an exploded view of a second embodiment of the
insert.
[0011] FIG. 4 shows a schematic view of a system including the
second embodiment of the insert.
[0012] FIG. 5 shows an exploded view of a third embodiment of the
insert.
[0013] FIG. 6 shows a schematic view of a system including the
third embodiment of the insert.
[0014] FIG. 7 shows an exploded view of a fourth embodiment of the
insert.
[0015] FIG. 8 shows a schematic view of a system including the
fourth embodiment of the insert.
DETAILED DESCRIPTION
[0016] The present invention includes an insert suitable for
placement within or on a seat to provide heating, cooling,
ventilation or a combination thereof to a seat occupant. The insert
will include at least one layer, but preferably includes multiple
(e.g. three) layers and each of the layers may be a monolayer or a
plurality of layers (e.g. a laminate). The plurality of layers need
not be attached to each other but preferably are. More preferably,
the layers are attached to each other at least at their edges to
form an edge-sealed bag. The layers of the insert are typically
co-extensive, although partial layers that are not co-extensive
with the other layers or the insert may be suitable in certain
instances.
[0017] The insert and the layers that make up the insert typically
have a seat portion and an extension. As the name suggests, the
seat portion generally is the area of the insert that will provide
heating, cooling, ventilation or combinations thereof to the area
of the seat where the seat occupant resides. The extension permits
components of a system including the insert to be remote from the
seat portion. This allows the components to be conveniently located
so that they do not interfere with the comfort of the seat. While
typically the extension is located at the back of the seat, it may
be located on either side, in the front of the seat or absent
altogether. Multiple extensions may also be used on an insert.
[0018] Typically, the insert is supported by a seat cushion or
backrest cushion. The seat cushion or backrest cushion may include
one or more ducts that extend partially or completely through the
cushion, or the cushions may be free of ducts that extend through
the cushion. A preferred cushion is a molded plastic foam, which is
preferably free of a molded or cut-out fluid distribution ducting
network, but may be adapted with a trench or opening for passing
the extension from one side of the cushion to the another side. The
seat cushion and/or backrest cushion may in turn be supported by a
seat frame. Multiple inserts may be used on a single seat or
backrest cushion, where inserts may accomplish the same or
different functions (e.g. one insert may only cool, while another
insert may both heat and cool).
[0019] One or more different kinds of layers may be used to make up
the insert. For example, the insert may include one or more spacers
to provide an open space within the insert. One or more flow
control layers may be included to provide selective flow of fluid
between one or more layers of the insert, between the insert and
the rest of the seat, or between the insert and the ambient. One or
more fluid barriers may be included. Other optional layers include
layers that include heaters, coolers, one or more additional
spacers, one or more covering layers, and/or one or more layers
that assist in the manufacture of the insert.
[0020] The spacer may be any structure, material or combination of
materials and/or structures that permits fluid flow through the
material while also providing a measure of support for a seat
occupant. The spacers should not collapse under the weight of a
seat occupant and maintain the fluid communication through the
spacer. As one example, the spacer may include rubber, foam plastic
or the like. In one aspect, the spacer may include a reticulated
foam or springs.
[0021] The spacer may include a plurality of members or fibers that
are preferably spaced apart from each other to provide open space
therebetween while still being close enough together to provide
cushion and support. One preferred spacer is formed of polymeric
(e.g., polyester) strand material that is interwoven to provide
opposing honeycomb structures (e.g., fabric panels), which are
interconnected by several additional polymeric strand materials to
provide open space between the structures while still providing
cushion and support. As an example, one preferred material is sold
under the tradename 3MESH.RTM. and is commercially available from
Muller Textil GmbH, Germany or Muller Textiles, Inc., Rhode Island,
USA.
[0022] Another preferred spacer is formed of a polymeric material
in a helix held between two sheets of material. Preferably, the
helix is oblong in order to provide increased area on the helix for
attachment of the helix to the sheets of material. The helix may be
tightly wound such that adjacent courses of the helix touch or
loosely wound such that there is no touching of adjacent courses of
the helix. Typically, multiple helices are placed adjacent
(abutting or otherwise) to one another in order to form a spacer.
Exemplary helical material is discussed in international
applications PCT/DE04/000540 and PCT/DE04/000541, both files Mar.
17, 2004, both of which are incorporated by references.
[0023] Another preferred spacer material is a grooved material. The
grooved material includes a plurality of hills and valleys, where
the hills have through holes. The grooved material may include any
suitable material such as a molded or shaped foam or plastic. The
flow holes may be made before, at the same time, or after the hills
and valleys.
[0024] Combinations of the above described materials may be used to
afford a spacer.
[0025] The flow control layer is typically formed of a plastic or
polymeric material that softens or melts upon exposure to heat to
assist its adherence to one or more other layers of the insert.
Alternatively, the flow control layer may be formed of fabrics,
woven materials (e.g., Goretex.RTM. or microfibers), nylon, closed
pore foam or other the like. Preferably, the flow control layer is
at least partially impermeable to fluids and particularly to air,
except at a plurality of through holes. The layer need not be
substantially impermeable to any fluid or air. Exemplary through
holes include ports (e.g. inlets and/or outlets), typically located
in the extension, and flow holes, typically located in the seat
portion.
[0026] Dimensionally, for a flow control layer, it is preferable
for the film thickness to be about 0.1 mm to about 2.0 mm thick and
more preferably about 0.7 mm to about 1.0 mm thick. Of course, it
is contemplated that the flow control layer may have a variable
thickness and may be outside of the aforementioned ranges.
[0027] The fluid barrier may be similar to the flow control layer
and may include the same or different materials as the flow control
layer. Preferably, the fluid barrier has similar composition and
dimensions as the flow control layer. Like the flow control layer,
the fluid barrier may include one or more ports, typically on the
extension of the insert. Unlike the flow control layer, the fluid
barrier does not comprise flow holes. Also like the flow control
layer, the fluid barrier is at least partially impermeable to
fluids and particularly to air, except at the ports. The fluid
barrier need not be substantially impermeable to any fluid or
air.
[0028] The ports and flow holes generally provide fluid
communication across the fluid barriers and the flow control
layers. The flow holes are generally located on the seat portion of
the insert. The pattern of the flow holes on each flow control
layer may be the same or different. In one preferred layout, the
size of the flow holes varies in a gradient across the seat portion
of the insert. Typically, the flow holes will be larger near the
front of the seat as compared to the back of the seat; however,
this is not necessarily the case. By creating a gradient of size in
this way, fluid flow through the flow control layer at various
locations may be selected. In another preferred layout, the flow
holes roughly correspond to the area of the seat where an occupant
would make contact with the seat.
[0029] Exemplary optional layers include those having a heater.
Various different types of heaters are suitable for incorporation
into a car seat and it is contemplated that any of such beaters may
be incorporated into the inserts of the present invention. Such
heaters typically incorporate flexible, electrical heating elements
that are preferably thin, flat, non-obtrusive or a combination
thereof. As examples, a lay-wire heater, a carbon fiber heater, a
positive thermal coefficient (PTC) heater, a thermoelectric heater
or the like, which are typically supported with a backing (e.g., a
cloth or fabric type backing) may be used within the insert. In a
preferred embodiment, the heater is a carbon fiber type heater with
a backing (e.g., a non-woven layer). One exemplary preferred heater
is sold under the tradename CARBOTEX.RTM. and commercially
available from W.E.T. Automotive Systems, Inc. in Germany and/or
FTG Fraser-Technik GmbH. An example of such a heater is disclosed
in U.S. Pat. No. 6,064,037, issued May 16, 2000, herein expressly
incorporated by reference for all purposes. A combination
heater/cooler in the form of a flexible sheet of TEDs may be a
suitable optional layer. Flexible sheet TEDs include those
discussed in U.S. Pat. No. 6,700,052, which is incorporated by
reference. Other coolers may includes those described in U.S.
provisional application 60/505,806, filed Sep. 25, 2003, which is
incorporated by reference.
[0030] The optional additional spacer may be the same or different
material as used for spacers in other parts of the insert. A
preferred optional additional spacer includes a reticulated
foam.
[0031] Suitable optional covering layers include seat covers that
are part of the insert or separate from the insert, but generally
separate the insert from the seat occupant. The seat cover may be
any suitable material, including but not limited to at least one
synthetic material, natural material (e.g., wool, leather or
otherwise), or combination thereof. In one embodiment the seat
cover includes perforations over at least a portion of the seating
surface through which air or other fluid may pass. In another
embodiment the cover is substantially free of perforations. For
example, perforated or non-perforated leather may be used to
separate the seat occupant from the insert, while a fleece material
may be used as part of the insert to increase moisture wicking or
otherwise provide a protective layer.
[0032] The additional spacer and the seat cover may have an area
that is co-extensive with the insert or they may have areas that
are greater or lesser than that of the insert.
[0033] One or more adhesive layers may be used to assist in the
assembly of the inserts. The adhesive layers are preferably formed
of a hot melt adhesive although this is not necessarily required.
The adhesive may be provided as a web or otherwise and may be
continuous or non continuous (e.g., may be applied in drops, dabs
or the like). The adhesive sub-layers may include polyamides,
polyesters, elastomers, urethanes, olefin polymers or a combination
thereof. Moreover, the adhesives may be formulated as desired for
particular processing parameters or conditions. Preferably, the
adhesive sub-layers are substantially free of anti-blocking
solutions, blowing additives, process contaminants or the like
which might interfere with adhesive performance. As an example, one
suitable hot melt adhesive is commercially available as a non-woven
web under the tradename SPUNFAB.RTM. from Spunfab, Ltd. 175 Muffin
Lane, Cuyahoga Falls, Ohio 44223.
[0034] The insert of the present invention may be a separate unit
that is assembled in a space between a seat cushion and the seat
cover, integrally formed in the seat cushion, integrally formed in
the seat cover, or any combination thereof.
[0035] In addition to the insert, the present invention includes a
system that provides heating, cooling, ventilation or combinations
thereof. The system has an insert and one or more different
components that facilitate the operation of the insert. For
example, the system may include a fan, a fluid conditioning device,
one or more attachment components, one or more valves, one or more
sensors and/or one or more controls. In addition, one or more
conduits may be used to provide fluid communication between
components of the system such as between the fan and the insert or
between the insert and the fluid conditioning device.
[0036] The fan provides motive force to move air (whether
conditioned, ambient, pushed, pulled and combinations thereof)
through the insert. The fan may be used to push air to the insert
or pull air from the insert. The fan may also be used to both push
and pull air. For example, at least two sets of fan blades (e.g.
with vanes that are opposite in direction) that share a common axis
and form a binary fan that is able to both push and pull air.
Multiple fans may also be used. The fan may also include an annular
inlet, although fan that are free of annular inlets are also
contemplated. Included in the definition of fan are impellers
(including bidirectional impellers), blowers, or the like. The fan
also refers to devices that provide motive force to move other
fluids (e.g. liquids) through the insert. The fan may provide a
steady fluid flow, a pulsating fluid flow, an oscillating fluid
flow, or the like.
[0037] The fluid conditioning device may be any device that heats
or cools fluid. The device may be a combination of devices where
one component provides heating and another component provides
cooling. Preferably, one device or system provides both heating and
cooling. The device may be an external device such as the HVAC
system in the building or vehicle where the seat is located or an
internal device meaning that the device is not connected (other
than to a power supply) to the building or vehicle where the seat
is located. In addition to providing temperature conditioning the
fluid conditioning device may also dehumidify the fluid (e.g.
air).
[0038] Preferably, the fluid conditioning device is a self
contained or solid state device that both cools and heats air. The
most preferred device is a peltier or thermoelectric device (TED).
TEDs are commercially available devices that provide solid state
heating and cooling by passing electricity through the device. TEDs
include a waste side and an active side, which are relative
designations depending whether warm or cool temperature conditioned
air is desired. Any supplier of TEDs would be able to provide
suitable devices for use in the present invention, with TEDs from
Tellurex (Telluride, Colo.) being preferred. The TED may be
combined with any useful heat dissipation device; e.g. heat sinks,
heat exchangers, fans, heat pipes or the like.
[0039] The attachment component is a frame member that preferably
defines a location for the attachment of the fan, fluid
conditioning device, a conduit or other component to the insert. It
is contemplated that the frame member may be in a variety of
configurations (e.g., annular, rectangular, square, polygonal or
otherwise) and may be formed of a variety of preferably rigid or
semi-rigid materials (e.g. metal, plastic or the like). In some
aspects, the attachment component also helps define a port. In one
preferred embodiment, the attachment component cooperates with
structures and/or materials (e.g. snap fit fasteners) on the fan,
the fluid conditioning device or other components to connect the
device or component to the attachment component.
[0040] One or more valves may be used to redirect fluid flow
through the system to make use of unused energy (i.e. the fluid is
hotter than ambient) or energy capacity (i.e. the fluid is colder
than ambient) in the fluid. For example, the valves may be used to
vent fluid to ambient to dispose of un-needed energy stored in the
fluid. The valves may also be used to redirect fluid to components
of the system (e.g. the fluid conditioning device) to either warm
or cool such components. In addition, a valve may be used to
optionally recirculate fluid within system to create a closed or
partially closed system.
[0041] A variety of sensors may be included in the system such as
temperature sensors, humidity sensors, current sensors, occupant
detection sensor, weight sensors or the like. Sensors may be placed
throughout the system. For example, temperature sensors may be
place within the spacer, between spacers, between the spacer and
any additionally optional layer (e.g. reticulated foam or seat
cover), near the fluid conditioning device, near the fan, and
combinations thereof.
[0042] One or more controllers may be used to receive inputs from
the sensors or a used control device, to issue instructions to the
fan and fluid conditioning device, and/or to otherwise coordinate
the operation of the system.
[0043] The embodiments of the inserts and systems discussed below
utilize air as the temperature conditioned fluid communicated
through the insert and/or system. It should be understood, however,
that other gas and/or liquid fluid may also be utilized in these
embodiments.
[0044] As seen in FIG. 1, the first embodiment of the insert 10
generally includes a seat portion 12 and an extension 14. The
insert also includes a first flow control layer 16, a first spacer
18, a second flow control layer 20, a second spacer 22 and a first
fluid barrier 24. Here, the spacers comprise a polymeric strand
material. In a preferred embodiment, these layers are sealed
together at least at their edges to form an edge sealed bag.
[0045] Both the first flow control layer 16 and the first fluid
barrier 24 include at least one port 26 and 28, respectively. The
ports are generally located on the extension of the insert and
provide access to the spacers. Instead of in the first fluid
barrier, the port 28 may be located laterally to the second spacer
layer. In this aspect, the port is defined by the extensions of the
second flow control layer and the first fluid barrier. In another
aspect, the port may be located in the second flow control layer
20. Here, a partial fluid barrier 30 (shown in phantom) would be
needed to separate the neck of the second flow control layer 20
from the neck of the first spacer 18.
[0046] The flow control layers include a plurality of flow holes
32. The flow holes are generally located on the seat portion of the
insert. The pattern of the flow holes on each flow control layer
may be the same or different.
[0047] In another aspect, the first flow control layer may be
replaced with a second fluid barrier with a port on the extension.
This provides an insert that would not blow or draw air to or from
the seat occupant. In yet another aspect, the first flow control
layer may be replaced with a combination of reticulated foam on the
seat portion and a fluid barrier on the extension. The fluid
barrier would include a port.
[0048] In a system including the insert of the first embodiment,
the fan is attached to the insert at one of the ports.
Alternatively, a conduit connects a fan to the insert at either of
the two ports. Such attachment may be facilitated by an attachment
component. The fan may be configured to either pull air out of the
insert or push air into the insert.
[0049] The system including the first embodiment of the insert also
preferably includes an fluid conditioning device in the form of a
TED. The TED may be located remote from the insert and the fan, but
this is not necessarily so. Indeed, the TED may preferably be
placed adjacent to the insert or attached to the insert with an
attachment component. The TED is preferably positioned such that
air flow across both the waste and active sides of the TED is
possible through the use of a single fan. In addition, the TED may
be placed relative to the fan such that conditioned air from the
active side of the TED is either pushed to the spacers or pulled
from the spacers. Conduits may be used to achieve the desired air
flow.
[0050] In a preferred embodiment, as shown schematically in FIG. 2,
the insert 10 includes two flow control layers 16 and 20 and the
fan 34 pulls air across the active side 36 of a TED 38 and through
the spacers 18, 22, while also pulling air across the waste side 40
of the TED. This aspect is shown with an optional additional spacer
42. The air flow is indicated schematically by the arrows in FIG.
2. In the alternative, the fan may push air across the waste side.
In one preferred embodiment, the active side of the TED is cooling
the air being drawn across it by the fan, while the waste side of
the TED is having heat evacuated from it by the fan. The
temperature conditioned air is routed through the spacers to
provide the seat occupant with a cooling sensation.
[0051] In one aspect, the second flow control layer permits ambient
air (i.e. air not conditioned by the fluid conditioning device)
from near the seat occupant to be drawn by fan to provide
additional ventilation and cooling. Such a configuration is shown
in FIG. 2, where the arrows indicate that air is drawn through the
top of the insert. In another aspect, a second fluid barrier is
used in place of the first flow control layer, which prevents
ambient from being drawn from near the seat occupant.
[0052] As seen in FIG. 3, the second embodiment of the insert 100
is similar to the first embodiment with the first spacer 102
including a grooved material 104. The use of the grooved material
makes the use of the first flow control layer 106 (shown in
phantom) optional. The insert also includes a second spacer 108 and
a fluid barrier 110. The grooved material 104 includes a plurality
of hills 112 and valleys 114, the hills include a plurality of flow
holes 116. In the aspect shown in FIG. 3, the grooved material
makes up only a portion of the first spacer and another spacer
material (e.g. polymeric strand material) makes up the remainder of
the first spacer. Alternatively, the first spacer may be completely
made up of the grooved material. While generally parallel hills and
valleys are preferred, other arrangement of hills and valleys may
also be suitable. Typically, when the first spacer is entirely
grooved material, the valleys will extend from the seat portion to
the port area in the extension. In this aspect, the flow holes may
only be located on hills in the seat portion of the insert. In this
embodiment, a partial fluid barrier 118 may be needed between the
extensions of the spacers to facilitate air flow through the seat
portions of the spacers.
[0053] Like the system including the first embodiment of the
insert, the system including the insert of the second embodiment
makes similar use of a fan and TED. As described above, the fan and
TED may be combined in a variety of ways in the system.
[0054] In a preferred embodiment of the system, as shown
schematically in FIG. 4, a fan 120 is positioned to draw air across
the active side 122 of a TED 124 through the second spacer 108,
through the flow holes 116, down the valleys 114 toward the fan and
across the waste side 126 of the TED, as shown by the arrows. Here,
a fluid barrier may be used to prevent the fan from drawing ambient
air from near the seat occupant. This aspect is shown with an
optional additional spacer 128.
[0055] As seen in FIG. 5, in a third embodiment of the insert 200
generally includes a seat portion 202 and an extension 204. The
insert also includes a flow control layer 206, a spacer 208, and a
fluid barrier 210. A second fluid barrier may be substituted for
the flow control layer 206.
[0056] The spacer 208 includes a main portion 212 with a cutout 214
therein. An inlay 216 is adapted to be received within the cutout
214. In an alternate embodiment, the relative positions of the main
portion and the inlay are reversed such that the inlay at least
partially surrounds the main portion. This embodiment is similar to
the fourth embodiment (discussed below) where the conduit comprises
a spacer material
[0057] The main portion and the inlay may be the same or different
materials from each other and their materials are typically
selected from the spacer materials discussed above.
[0058] When the inlay 216 is assembled with the main portion 212
(i.e. inlaid in the main portion) there is a fluid barrier 218 that
at least partially creates a fluid-tight boundary that prevents
fluid communication between the main portion 212 and the inlay 216
of the spacer.
[0059] Typically, when assembled, the inlay resides both in the
extension and the seat portion of the insert. While shown in FIG. 5
as being un-branched, the inlay may take on a variety of branched
shapes, such a Y-shape where the arms of the Y reside in the seat
portion while the tail resides in the extension of the insert. A
"branches-on-branches" configuration may also be suitable.
Generally, only one inlay is preferred, but multiple inlays may be
suitable.
[0060] The fluid barrier may located on or about the inlay, in the
main portion or be a separate component from both the main portion
and the inlay. In one preferred aspect, the fluid barrier is
included in the inlay.
[0061] The inlay includes a port 220 in the fluid barrier that
provides fluid communication to the interior of the inlay. The port
is typically located in area of the inlay that resided on the neck
of the insert. The inlay also preferably includes a plurality of
flow holes 222 in area of the inlay that resides in the seat
portion of the insert. These flow holes may be aligned parallel to
the plane of the insert, normal to the plane of the insert, or at
some other angle. The flow control sheet includes a port 223
aligned with the main portion and that provides fluid communication
to the interior of the main portion.
[0062] In one aspect, the inlay may comprise a strand material, a
grooved material or a reticulated foam material. With the grooved
material it may not be necessary to utilize the fluid barrier on or
around the inlay.
[0063] Like the systems including the first and second embodiments
of the insert, the system including the insert of the third
embodiment makes similar use of a fan and TED. As described above,
the fan and TED may be combined in a variety of ways in the
system.
[0064] In a preferred embodiment of the system, as shown
schematically in FIG. 6, the insert 200 includes a fan 224 that
pulls air across the active side 226 of a TED 228 and through the
inlay 216 to the main portion 212 or to an optional additional
spacer 230 via flow holes. The fan also pushes air across the waste
side 232 of the TED. In the alternative, the fan may pull air
across the waste side. In one preferred embodiment, the active side
of the TED is cooling the air being drawn across it by the fan,
while the waste side of the TED is having heat evacuated from it by
the fan. The temperature conditioned air is routed through the
inlay and main portions of the spacer to provide the seat occupant
with a cooling sensation.
[0065] As seen in FIG. 7, in a fourth embodiment of the insert 300
generally includes a seat portion 302 and an extension 304. The
insert also includes a flow control layer 306, a spacer 308, a
fluid barrier 310 and at least one conduit 312. Preferably, a
plurality of conduits is used. In one embodiment, a second fluid
barrier may be substituted for the flow control layer 306.
[0066] The conduit provides fluid communication to or from the seat
portion of the insert. Preferably, the conduit is generally located
along the edge of the seat portion or the extensions of the insert.
In the alternative, the conduit may extend into the seat portion of
the insert.
[0067] The conduit comprises one or more flow holes 314 located on
the seat portion of the conduit. The flow holes may have one or
more directions, i.e. generally normal to the place of the insert,
generally in the same plane as the plane of the insert, or any
angle in between. The conduit may be held within the insert
(whether the insert is a sealed bag insert or not), attached to the
exterior of the insert or formed as part of the insert. In a
preferred embodiment, the conduit is located underneath the flow
control layer and in the plane of the insert. As seen in the FIG.
8, the conduit may be located above the flow control layer.
[0068] The conduit is preferably made of a flexible tubing material
that is distinct from the material of the spacer, although this is
not necessarily the case. Suitable flexible tubing material
includes tubing with wall thicknesses ranges from about 1/64 in to
about 1 in or more. The material of suitable tubing may be selected
to provide low thermal capacity, meaning that tubing does not
insulate well. The conduit may also comprise spacer material that
is sectioned from the insert by a fluid-tight barrier. While
generally part of the insert, the conduit may be used to replace
other components of a seat (e.g. as a front or side bolster) or may
be used augment other components of a seat (e.g. the additional
spacer layer).
[0069] Like the systems including the other embodiments of the
insert, the system including the insert of the fourth embodiment
makes similar use of a fan and TED. As described above, the fan and
TED may be combined in a variety of ways in the system. A port 316
for the fan is generally located on the extension of the insert,
while the TED is preferably co-located with the extension of the
insert; more preferably it is attached to extension.
[0070] In a preferred embodiment of the system, as shown
schematically in FIG. 8, the insert 300 includes a fan 318 that
pulls air through the spacer 308 and/or through the additional
spacer 320 from the flow holes of the conduit 312. The fan pulls
the air across the active side 322 of a TED 324 through a manifold
to the flow holes of the conduit. The fan also pushes air across
the waste side 326 of the TED. In the alternative, a second fan is
used to push air across the active side of the TED through the
manifold to the flow holes of the conduit.
[0071] In one preferred embodiment, the active side of the TED is
cooling the air being drawn across it by the fan, while the waste
side of the TED is having heat evacuated from it by the fan. The
temperature conditioned air is routed through the spacer to provide
the seat occupant with a cooling sensation.
[0072] Depending on the location of the conduit and the flow holes,
the temperature conditioned air may flow directly to or from the
conduit to the spacer. Alternately, the air may flow through
another material between the conduit and the spacer. In this way,
the temperature conditioned air is pulled (and/or pushed) across
the surface of the insert. For example, the air may flow through or
over any of the optional layers discussed above such as an
additional spacer (e.g. reticulated foam) or a covering (e.g.
perforated leather).
[0073] In a preferred embodiment, the temperature conditioned air
flows into the additional spacer and ambient air flows through the
seat cover into the additional spacer, where the air mixes. The
mixed air flows into the spacer material of the insert because of
the pulling of the fan. In another preferred embodiment, the mixed
air does not flow. This may be achieved by through selection of the
size and power of the fan(s) used in the system. In a one fan
system, the fan should produce a negative pressure in the
additional spacer. In a two or more fan system, any fans that push
air through the manifold to the flow holes of the conduit should
produce a positive pressure that is less than the negative pressure
produced by the fan that pulls air through the insert.
[0074] In one optional embodiment, a valve (not shown) is utilized
to redirect temperature conditioned air before it flows through the
spacer. Such redirected air may be vented to ambient because the
insert has reached the desired temperature. Such redirected air may
also be shunted to the waste side of the TED to help dissipate
waste energy.
[0075] In another optional embodiment, a valve is utilized to
recirculate temperature conditioned air after it has flowed through
the spacer. Such recirculated air may have a temperature that is
closer to the desired temperature than that of ambient air. For
example, when the TED is in the cooling mode, the recirculated air
may be cooler than ambient air. Thus, it would be more efficient to
cool the recirculated air to the desired temperature than it would
be to cool the ambient air.
[0076] In another embodiment, the present invention comprises a
ventilated seat a perforated seating surface that supports a seat
occupant and a mixing region that is located under the seating
surface where ambient air is combined with a cooled fluid. A fan
may be use to bring ambient air into the mixing region. The fan may
also function to bring the cooled fluid to the mixing region or to
remove the mixed ambient air and cooled fluid from the mixing
region. As discussed above, a fluid conditioning device may be used
to modify (e.g. reduce) the temperature of the fluid.
[0077] In one embodiment, it is contemplated that the control
system is employed to automatically change the power provided to
the TED when a certain temperature has been reached or after a
certain period of time. Less preferably, though also possible, the
system automatically changes the power based upon a combination of
both a sensed temperature and a certain period of time. In this
regard, one system of the present invention preferably
automatically regulates only one of the amount of power directed to
the TED or the operating speed of the fan or the like to achieve
the desired cooling temperature. However, one embodiment also
contemplates the automatic regulation of both the amount of power
directed to the TED and the operating speed of the fan. It is
preferred that the operation of the system of the present invention
is done independent of any signal from an occupant detection senso,
if any. However, it is possible that an occupant detection sensor
is employed in communication with a control system for
automatically operating the system upon detection of the presence
of a user.
[0078] The present invention also relates to the methods of
providing heating, cooling, ventilation or combination thereof. One
method includes pulling air across an active side of a TED, through
one or more spacers and across a waste side of the TED. Another
method includes pulling air across an active side of a TED, through
an inlay, through a main portion of a spacer, and across a waste
side of the TED. Yet another method includes pulling air across an
active side of a TED, through a conduit, through a spacer and
across a waste side of the TED. In all of these methods, the air
may be pushed across the waste side of the TED. Furthermore,
instead of generally pulling the air, pushing the air may be
utilized. It will be recognized that the in the above methods other
fluid conditioning devices besides TEDs may be used and that fluids
other than air may be moved by the fan.
[0079] In another embodiment, the method comprises drawing ambient
air through a seating surface of a transportation vehicle seat into
a mixing region of the seat. In the mixing area, the ambient air is
mixed with air cooled by a thermoelectric device and provided to
the mixing region. In one embodiment, the pressure in the mixing
region below the ambient pressure so that substantially all of the
resulting mixture does not pass through the seating surface. In
another embodiment, cooled air is blown into the mixing region
while substantially all the resulting mixture is kept from passing
through the seating surface. In either embodiment, the resulting
mixture is removed from the mixing region. In one embodiment, the
mixing region is located within an insert. In another embodiment,
the mixing region is disposed between an insert and a seating
surface.
[0080] In a preferred embodiment, the present invention provides
cooling from above about 100.degree. C. and more preferably
provides cooling from about 80.degree. C. Also, the present
invention provides cooling to below about 37.degree. C., and more
preferably to below about 27.degree. C., and most preferably below
about 25.degree. C. These temperatures may refer to air temperature
within the insert, anywhere within the system or the temperature at
or near the seat surface. In one preferred embodiment, the present
invention provides cooling at a rate of greater than about
5.degree. C./min, greater than about 10.degree. C./min, greater
than about 15.degree. C./min and greater than about 20.degree.
C./min, greater than about 25.degree. C./min and greater than about
35.degree. C./min.
[0081] Preferably, the insert and the system may be included in a
seat used in a transportation vehicle (e.g. an automotive vehicle
seat); however, the insert and system may be used in a variety of
other seats such as desk chairs, lounge chairs, or the like.
[0082] Generally, for forming an insert according to the present
invention, it is contemplated that the various layers of the insert
as described above may be combined in a variety of sequences and
according to a variety of protocols and techniques. Thus, the order
in which the various layers and sub-layers are combined and the
techniques of combining should not in any way limit the present
invention unless such order or techniques is specifically claimed.
Moreover, it is also contemplated that there may be greater or
fewer layers and that each layer may include greater or fewer
sub-layers.
[0083] In general, a lamination process is preferred to assemble
the layers of the inserts. U.S. patent application Ser. No.
10/434,890, filed on May 9, 2003, hereby incorporated by reference,
includes a discussion of one suitable technique for assembling the
layers of inserts according to the present invention.
[0084] For assembly of the insert or system to a seat, the insert
is preferably secured (e.g., sewn, adhered or otherwise attached)
to a portion of the seat such as the cover (e.g., a perforated
leather cover) or to a seat or backrest cushion (e.g., foam) of the
seat. In one embodiment, the insert is first secured to a seat
cover and then the seat cover is secured to the seat. For example,
the insert may be joined to seat cover at the edges of the insert
or it may be joined to the seat cover at locations other than along
the edges of the insert.
[0085] In another embodiment, a seat cover may be configured to
include a pocket for receiving the insert. Alternatively, it is
contemplated that hook and loop fasteners may be utilized to attach
the insert to portions (e.g., the cover, frame, seat cushion or
backrest cushion) of the seat. Other techniques may be used to
assemble the insert to the seat such as sewing, adhesives, snap-fit
fasteners or locating pins. Furthermore, the insert may be attached
to other components of the seat such as the seat frame.
[0086] By packaging the components of the system substantially
entirely within a seat of the present invention, rather than
external thereof, it is possible to realize various advantages,
such as ease of manufacturing and assembly. For example, it is
possible to assemble all of the functional components at a remote
assembly site, and thereafter transport a seat to an automotive
assembly line, where the seat is merely mounted to the body in
white and connected to the vehicle electrical system. In contrast,
other systems might rely upon a cooling device that is located
external of a seat to provide cooled air to the seat. Though such
systems are within the scope of certain embodiments of the present
invention, they are less preferred.
[0087] It will be further appreciated that functions or structures
of a plurality of components or steps may be combined into a single
component or step, or the functions or structures of one-step or
component may be split among plural steps or components. The
present invention contemplates all of these combinations. Unless
stated otherwise, dimensions and geometries of the various
structures depicted herein are not intended to be restrictive of
the invention, and other dimensions or geometries are possible.
Plural structural components or steps can be provided by a single
integrated structure or step. Alternatively, a single integrated
structure or step might be divided into separate plural components
or steps. In addition, while a feature of the present invention may
have been described in the context of only one of the illustrated
embodiments, such feature may be combined with one or more other
features of other embodiments, for any given application. It will
also be appreciated from the above that the fabrication of the
unique structures herein and the operation thereof also constitute
methods in accordance with the present invention.
[0088] The explanations and illustrations presented herein are
intended to acquaint others skilled in the art with the invention,
its principles, and its practical application. Those skilled in the
art may adapt and apply the invention in its numerous forms, as may
be best suited to the requirements of a particular use.
Accordingly, the specific embodiments of the present invention as
set forth are not intended as being exhaustive or limiting of the
invention. The scope of the invention should, therefore, be
determined not with reference to the above description, but should
instead be determined with reference to the appended claims, along
with the full scope of equivalents to which such claims are
entitled. The disclosures of all articles and references, including
patent applications and publications, are incorporated by reference
for all purposes.
* * * * *